Liquid crystal display and method of manufacturing the same

ABSTRACT

The invention relates to a liquid crystal display in which a polymeric component included in a liquid crystal layer is polymerized while adjusting a voltage applied to the liquid crystal layer to regulate the direction of alignment of liquid crystal molecules during polymerization and a method of manufacturing the same. The invention provides a liquid crystal display in which image sticking is mitigated and a method of manufacturing the same. In a method of manufacturing a liquid crystal display in which a liquid crystal composition including a polymeric component that is optically or thermally polymerized is sealed between substrates and in which the polymeric component is polymerized while applying a voltage to the liquid crystal composition to regulate the direction of alignment of liquid crystal molecules during driving, a configuration is employed such that a polymerization initiator in the liquid crystal composition has a concentration x that satisfies 0≦x≦0.002 (% by weight)

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a liquid crystal display (LCD) in whicha liquid crystal material including a polymeric component (a monomer oroligomer) that is optically or thermally polymerized is sealed betweensubstrates and in which the polymeric component is polymerized to form apolymer while adjusting a voltage applied to the liquid crystal layer(the applied voltage may be zero, and this operating may be hereinaftersimply stated as “while applying a voltage” as occasions demand), thedirection of alignment of liquid crystal molecules being regulatedduring driving by the alignment regulating capability of the polymer,the invention also relating to a method of manufacturing the same.

Referring to liquid crystal displays utilizing an active matrixaccording to the related art, TN (twisted nematic) mode liquid crystaldisplays are widely used in which a liquid crystal material havingpositive dielectric constant anisotropy is aligned horizontally on asubstrate surface such that it is twisted at 90 degrees. betweensubstrates that are opposite to each other in a dark state. Such TN modeliquid crystal displays have a problem in that they have poor viewingangle characteristics, and various studies have been made to improve theviewing angle characteristics.

IPS mode (in-plane-switching mode) liquid crystal displays (hereinafterbriefly referred to as IPS-LCDs) in which a liquid crystal havingpositive dielectric constant anisotropy is horizontally aligned andapplied with a transverse electric field are known as liquid crystaldisplays that are better than TN mode liquid crystal display accordingto the related art in viewing angle characteristics. However, liquidcrystal molecules are switched in a horizontal plane with a comb-shapedelectrode in an IPS-LCD, and there is a need for a backlight unit havinghigh optical intensity because the comb-shaped electrode reduces theaperture ratio of pixels significantly.

On the contrary, multi-domain vertical alignment mode liquid crystaldisplays (hereinafter briefly referred to as MVA-LCDs) are known inwhich a liquid crystal having negative dielectric constant anisotropy isvertically aligned and in which banks (linear protrusions) are providedon a substrate or blanks (slits) are provide in an electrode as analignment regulating structure. An MVA-LCD exhibits excellent viewingangle characteristics because it is provided with an alignmentregulating structure which makes it possible to control the alignment ofthe liquid crystal such that it is oriented in a plurality oforientations when a voltage is applied without performing any rubbingprocess on alignment film.

However, the optical transmittance of the panel of an MVA-LCD is lowerthan that of a TN mode LCD although the reduction in the substantialaperture ratio of the pixels attributable to the protrusions or slits isnot as significant as that caused by the comb-shaped electrode of anIPS-LCD. For this reason, MVA-LCDs and IPS-LCDs are presently consideredunsuitable for notebook type PCs for which low power consumption is amust.

MVA-LCDs according to the related art have a problem in that it appearsdark when displaying white because of low luminance. This is principallyattributable to the fact that dark lines appear above protrusions orslits that are boundaries between separate alignments to reducetransmittance during white display and to consequently present darkappearance. Although this problem can be mitigated by maintainingsufficient intervals between the protrusions or slits, since thisresults in a decrease in the number of the protrusions or slits that arealignment regulating structures, another problem arises in that responsetime is increased because it takes a long time to stabilize thealignment of the liquid crystal when a predetermined voltage is applied.

In order to solve this problem and to provide an MVA-LCD having highluminance capable of high speed response, a method has been proposed inwhich the direction of alignment of liquid crystal molecules duringdriving is regulated using a polymer. According to the method ofregulating the direction of alignment of liquid crystal molecules duringdriving using a polymer, a liquid crystal material that is a liquidcrystal mixed with a polymeric component such as a monomer or oligomer(hereinafter briefly referred to as a monomer) is sealed betweensubstrates. The monomer is polymerized into a polymer with the liquidcrystal molecules tilted by applying a voltage between the substrates.This provides a liquid crystal layer that is tilted at a predeterminedpretilt angle even when voltage application is stopped. A material thatis polymerized by heat or light (ultraviolet rays) is chosen as themonomer.

However, in the case of an MVA-LCD manufactured according to the methodof regulating the alignment direction of liquid crystal molecules duringdriving using a polymer, when an image is displayed for a long time, theimage can remain visible (image sticking) even when the display isswitched. This problematically reduces display quality.

SUMMARY OF THE INVENTION

The invention provides a liquid crystal display whose displaycharacteristics are easily and reliably improved to achieve highlyreliable display by mitigating image sticking that is caused by themethod of regulating the alignment direction of liquid crystal moleculesduring driving using a polymer and provides a method of manufacturingthe same.

The above-described problem is solved by a liquid crystal display inwhich a liquid crystal material is sealed between two substratesprovided opposite to each other, characterized in that the liquidcrystal material includes a polymeric component that is optically orthermally polymerized, a polymerization initiator, and a liquid crystalcomposition and in that the polymerization initiator in the liquidcrystal material has a concentration x that satisfies 0≦x≦0.002 (% byweight).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates a liquid crystal display and amethod ofmanufacturing the same in a first mode for carrying out the invention;

FIG. 2 shows a step of irradiating a liquid crystal layer of an LCDpanel with ultraviolet rays with a voltage applied thereto;

FIG. 3 schematically illustrates another liquid crystal display and amethod of manufacturing the same in the first mode for carrying out theinvention;

FIG. 4 shows a relationship between the concentration of apolymerization initiator and an image sticking rate in the first modefor carrying out the invention;

FIG. 5 is a characteristic diagram showing a relationship betweenfrequencies of an AC voltage and image sticking rates.

FIG. 6 is a sectional view showing major features of a liquid crystaldisplay in a second mode for carrying out the invention;

FIG. 7 is a plan view showing a part of a pixel electrode formed withfine slits for forming an alignment pattern;

FIG. 8 is a sectional view showing how a liquid crystal layer is formed;

FIG. 9 schematically shows the definition of an average surfaceroughness;

FIG. 10 is a microphotograph (AFM image) showing a polymer structure onpixel electrodes having slits on the side of a TFT substrate; and

FIG. 11 is a characteristics diagram showing a relationship betweenaverage surface roughness of a polymer structure and image stickingrates.

THE DESCRIPTION OF THE PREFERRED EMBODIMENTS

A liquid crystal display and a method of manufacturing the same in afirst mode for carrying out the invention will now be described withreference to FIGS. 1 to 4. First, the liquid crystal display and themethod of manufacturing the same in the present mode for carrying outthe invention will be schematically described with reference to FIG. 1.FIG. 1 shows a pixel 2 of the liquid crystal display in the present modefor carrying out the invention as viewed in a direction normal to asurface of the substrate of the same. The pixel 2 is formed in arectangular region that is defined by gate bus lines 4 and drain buslines 6 that intersect each other with an insulation film which is notshown interposed therebetween. At the top left part of the pixel 2 inthe figure, there is formed a TFT 16 that serves as a switching elementwhen a gray scale voltage is applied to a pixel electrode to bedescribed later. In the pixel 2, connection electrodes 12 and 14 areformed like a cross to divide the pixel into four domains of alignmenthaving the same rectangular outline configuration. The connectionelectrode 12 is formed substantially in the middle of the pixel 2 inparallel with the drain bus lines 6, and the connection electrode 14 isformed on a storage capacitor bus line 18 that extends across the pixel2 substantially in the middle thereof.

A plurality of stripe-like electrodes 8 that are fine electrode patternsare repeatedly formed substantially at an angle of 45 degrees. to theconnection electrodes 12 and 14. A pixel electrode is formed by theconnection electrodes 12 and 14 and the plurality of stripe-likeelectrodes 8. The top left stripe-like electrodes 8 in the figure areelectrically connected to a source electrode of the TFT 16. A space 10is formed between stripe-like electrodes 8 that are adjacent to eachother, the space being in the form of a blank between the electrodes. Analignment regulating structure is formed by the stripe-like electrodes 8and the spaces 10. Obviously, fine linear protrusions may be formed onthe pixel electrode that is formed on the entire surface in the pixel 2instead of the stripe-like electrodes 8 and the spaces 10 in FIG. 1.Although not shown, an insulating structure or slits (that are obtainedby removing some parts of a common electrode through patterning) mayobviously be formed on an opposite substrate in association with thealignment regulating structure formed on the pixel electrode.

After forming such a fine line-and-space pattern on the pixel electrodeof the pixel 2 in the TFT substrate, vertical alignment films are formedon surfaces of the TFT substrate and an opposite substrate facing eachother. While various materials may be used for the vertical alignmentfilms, polyamic acid type alignment films may be used, for example.

The two substrates are then combined with a negative liquid crystalhaving negative dielectric constant anisotropy sealed therebetween. Thenegative liquid crystal contains a polymeric component in apredetermined ratio. A diacrylate monomer is used as the polymericcomponent.

FIG. 2 shows a step in which the liquid crystal layer of the LCD panelis irradiated with ultraviolet rays with a voltage applied thereto. Asshown in FIG. 2, the LCD panel is placed in a chamber of an ultravioletirradiation apparatus 32. Liquid crystal molecules in the liquid crystalcomposition are aligned substantially perpendicularly to the substratesurface before the monomer in the LCD panel is polymerized. Next, avoltage is applied between electrodes 34 and 36 which are provided onthe substrates of the LCD panel from a voltage application apparatus 30.Thus, the voltage is applied to a liquid crystal layer 38 sealed betweenthe electrodes 34 and 36 to tilt liquid crystal molecules in the pixel 2in a predetermined direction. The surface of the LCD panel is irradiatedwith ultraviolet rays (UV rays) from a high pressure mercury lamp (notshown) of the ultraviolet irradiation apparatus 32 while keepingapplying the voltage from the voltage application apparatus 30. As aresult, the liquid crystal material added with a monomer is irradiatedwith ultraviolet rays to polymerize the monomer into a polymer whichregulates the direction of alignment of the liquid crystal moleculesduring normal driving.

FIG. 3 shows a pixel 2 of an MVA-LCD having a different configuration asviewed in a direction normal to a surface of the substrate thereof. Theconfiguration shown in FIG. 3 is characterized in that a pixel electrode3 on a TFT substrate on which a TFT 16 is formed is a stripe-likeelectrode having a line-and-space pattern. As shown in FIG. 3, the pixelelectrode 3 has stripe-like electrodes 8 and spaces 10 that are formedin a line-and-space pattern in parallel with a drain bus line 6.

The stripe-like electrodes 8 are electrically connected by a connectionelectrode 14 that is formed substantially in the middle of the pixel 2in parallel with a gate bus line 4. Some of the stripe-like electrodes 8are connected to a source electrode 22 provided in a face-to-facerelationship with a drain electrode 20 of the TFT 16.

A linear protrusion extending in parallel with the gate bus line 4 isformed in a position on an opposite substrate that is not shown, theposition facing the connection electrode 14 in the middle of the pixelregion. The direction in which the alignment of liquid crystal moleculesis to be regulated can be more clearly determined by the linearprotrusion.

A liquid crystal material added with a monomer is irradiated withultraviolet rays to polymerize the monomer with the liquid crystalmolecules in the pixel 2 tilted in a predetermined direction by applyinga voltage to the liquid crystal layer (not shown) in the same manner asthat in the configuration shown in FIG. 2, which makes it possible tostabilize a pretilt angle and/or alignment direction of the liquidcrystal molecules.

Various monomers, polymerization initiators, and liquid crystalcompositions (liquid crystal molecules) were studied in an intention tomitigate image sticking in LCDs manufactured using the above-describedmethod of manufacture attributable to the use of the method ofregulating the alignment direction of liquid crystal molecules duringdriving using a polymer. As a result, it was revealed that apolymerization initiator causes image sticking, although the initiatoris effective in reducing the optimum irradiation amount of ultravioletrays to improve production efficiency. In the case of an LCD in whichthe alignment direction of liquid crystal molecules during theapplication of a voltage is regulated using a polymer, the LCD has moresignificant image sticking on images displayed thereby when it iscompleted, the higher the concentration of the polymerization initiatorfor promoting initiation of polymerization of the monomer whenirradiated with ultraviolet rays, although the time required forpolymerization is reduced. When no polymerization initiator is added inthe liquid crystal material at all, the LCD has a lower level of imagesticking on images displayed thereby when it is completed, althoughpolymerization takes a longer time. Therefore, a polymerizationinitiator preferably has a low concentration in order to mitigate imagesticking.

That is, image sticking can be reduced by adding no polymerizationinitiator for a monomer in a liquid crystal material or polymerizing themonomer with the initiator in a very small dose.

Let us assume that x represents the concentration of a polymerizationinitiator in a liquid crystal material before polymerization (in % byweight, which applies to the following concentrations); y represents theconcentration of a monomer in the liquid crystal material beforepolymerization; z represents the concentration of a liquid crystalcomposition in the liquid crystal material before polymerization; and αrepresents an image sticking rate. Then, the concentration x of thepolymerization initiator preferably satisfies 0≦x≦0.002 (% by weight).In particular the image sticking rate α is minimized when x=0. Themonomer concentrationy is desirably in the range from 0.1 to 10% byweight inclusive in consideration to the image sticking rate α.

The image sticking rate α is determined as follows. A black-and-whitechecker pattern is displayed on a display area of an LCD for a longtime. Then, a predetermined halftone is displayed throughout the displayarea; a difference (β−γ) between luminance β of regions where white hasbeen displayed and luminance γ of regions where black has been displayedis identified; and the luminance difference (β−γ) is divided by theluminance γ of the regions where black has been displayed to determinethe image sticking rate.

That is:Image sticking rate α=((β−γ)/γ)×100 (%)

FIG. 4 shows a relationship between the concentration of apolymerization initiator and the image sticking rate. FIG. 4 shows theconcentration (% by weight) of a polymerization initiator on theabscissa axis thereof and shows the image sticking rate (%) on theordinate axis thereof. As described above, the concentration of apolymerization initiator is preferably 0.002% by weight or less, and theimage sticking rate α is minimized when no polymerization is added in aliquid crystal material at all. For a common viewer, an LCD has nopractical problem when it has an image sticking rate α of about 5 to 6%,and image sticking becomes noticeable at a rate of about 10%. The graphin FIG. 4 shows that the image sticking rate is 6% or less when theconcentration of the polymerization initiator is 0.002% by weight orless, and which provides characteristics that are practicallyacceptable. An image sticking rate α as very low as about 3% can beachieved in the case of a polymerization initiator concentration of 0%,i.e., when no polymerization initiator is used.

A liquid crystal display and a method of manufacturing the same in thepresent mode for carrying out the invention will now be specificallydescribed with reference to embodiments of the same and a comparativeexample. MVA-LCDs having the structure shown in FIG. 1 are used in theembodiments in the present mode for carrying out the invention and thecomparative example. Specifically, vertical alignment films are formed,and the liquid crystal has negative dielectric constant anisotropy. Twopolarizers facing each other with two substrates interposed therebetweenare provided in a crossed Nicols configuration to enable the normallyblack mode in which black is display when no voltage is applied.Polarization axes of the polarizers which are not shown are indirections substantially in parallel with or perpendicular to bus lines.The LCDs have a diagonal panel size of 15 inches and resolutionaccording to XGA.

(Embodiment 1)

A liquid crystal material was sealed between substrates, the liquidcrystal material being obtained by mixing a liquid crystal compositionhaving an average molecular weight of about 350 with 0.3% by weight ofphoto-setting diacrylate monomer having a molecular weight of about 350and 0.006% by weight of polymerization initiator. Next, the monomer waspolymerized with a voltage applied to the liquid crystal layer to causeit to memorize the tilting direction of the liquid crystal molecules.The ultraviolet rays for polymerizing the monomer were radiated at theroom temperature (20° C.) with irradiation energy of 10 J/cm² (they wereradiated using the same ultraviolet irradiation apparatus as that usedin the following comparative example 1 for a time that is ten times theultraviolet irradiation time of the comparative example 1). The MVA-LCDthus completed was caused to display a black-and-white checker patternfor 48 hours, and the image sticking rate α of the same was thereaftermeasured at 15%.

(Embodiment 2)

A liquid crystal material was sealed between substrates, the liquidcrystal material being obtained by mixing a liquid crystal compositionhaving an average molecular weight of about 350 with 0.3% by weight ofphoto-setting diacrylate monomer having a molecular weight of about 350and no polymerization initiator. Next, the monomer was polymerized witha voltage applied to the liquid crystal layer to cause it to memorizethe tilting direction of the liquid crystal molecules. The ultravioletrays for polymerizing the monomer were radiated at the room temperature(20° C.) with irradiation energy of 100 J/cm² (they were radiated usingthe same ultraviolet irradiation apparatus as that used in the followingcomparative example 1 for a time that is one hundred times theultraviolet irradiation time of the comparative example 1). The MVA-LCDthus completed was caused to display a black-and-white checker patternfor 48 hours, and the image sticking rate α of the same was thereaftermeasured at 3%.

Comparative Example 1

A liquid crystal material was sealed between substrates, the liquidcrystal material being obtained by mixing a liquid crystal compositionhaving an average molecular weight of about 350 with 0.3% by weight ofphoto-setting diacrylate monomer having a molecular weight of about 350and 0.008% by weight of polymerization initiator. Next, the monomer waspolymerized with a voltage applied to the liquid crystal layer to causeit to memorize the tilting direction of the liquid crystal molecules.The ultraviolet rays for polymerizing the monomer were radiated at theroom temperature (20° C.) with irradiation energy of 1 J/cm². TheMVA-LCD thus completed was caused to display a black-and-white checkerpattern for 48 hours, and the image sticking rate α of the same wasthereafter measured at 35%.

The LCD panels exhibited substantially the same optical characteristicsunder any of the conditions after they were irradiated with ultra violetrays. As apparent from Embodiments 1 and 2 and the comparative example1, when the concentration of a polymerization initiator is low or whenno polymerization initiator is added at all, image sticking of imagesdisplayed by a completed LCD can be significantly reduced.

[Second Mode for Carrying Out the Invention]

(Principle)

First, the principle of a second mode for carrying out the inventionwill be described.

The inventors have been developing an alignment regulating technique inwhich a monomer that is optically or thermally polymerized is mixed in aliquid crystal and is polymerized with a predetermined voltage appliedbetween substrates to achieve stable alignment as a technique forimproving MVA-LCDs, i.e., improving the aperture ratio of the same toincrease brightness and reducing the cost of the same.

However, it was revealed that the alignment regulating techniqueproblematically causes a liquid crystal panel to perform poorly withrespect to image sticking when it is driven compared to a panel thatdoes not employ a setting method utilizing a monomer material.

Although no practical problem occurs when an image sticking rate α ofabout 5 to 6% is achieved in the same way as that in the first mode forcarrying out the invention, an image sticking rate α of about 10%results in image sticking that is noticeable and no longer ignorable toa user.

Normally, a liquid crystal display is driven by applying a AC voltage tothe liquid crystal layer in order to prevent image sticking. However,since the pair of substrates sandwiching the liquid crystal layer havedifferent layered structures and different electrodes, a polarity isgenerated between the substrates to affect the AC voltage. As a result,even when an AC voltage of a constant value is applied to the liquidcrystal display from an external voltage application apparatus, thevoltage applied to the liquid crystal layer will have two differentvalues because of switching of the AC voltage. A change in the voltagecauses a change in the alignment or state of the liquid crystal.

Therefore, when an AC voltage having a frequency of 30 Hz for normaldriving is applied to the liquid crystal layer and a polymer structurefor controlling alignment is formed with the voltage kept applied, thealignment direction will be defined with irregularities in alignmentattributable to instantaneous voltage changes left unremoved.Irregularities in alignment cause image sticking on the liquid crystaldisplay to reduce the display characteristics of the same.

The inventors thought of increasing the frequency of an AC voltage to beapplied to a liquid crystal layer in order to prevent image sticking.

An examination of a relationship between AC voltage frequencies and theimage sticking rate α revealed that the image sticking rate α is at aminimum value of 5% or less at a AC voltage frequency of 60 Hz, as shownin FIG. 5. Since the image sticking rate α gradually increases at higherfrequencies (the sticking rate at 1 kHz substantially equals that at afrequency of 30 Hz), a proper frequency range is from 60 Hz to 1 kHz.

Such changes in the image sticking rate α are attributable to the factthat the speed of response of liquid crystal molecules becomes unable tofollow the speed of switching of the AC voltage when the AC voltagefrequency is greater than that for normal driving, e.g., twice the same(60 Hz). Thus, the alignment of the liquid crystal molecules is defineddepending on the state of the same at intervals between switching of theAC voltage instead of depending on the switching of the AC voltage. Byforming a polymer in this state, a liquid crystal display can beobtained which has less image sticking, no irregularity of alignment,and good display characteristics.

(Embodiment)

A specific embodiment will now be described based on the above-describedprinciple of the present mode for carrying out the invention. Thedescription will be made on a liquid crystal display having majorfeatures as shown in FIG. 6.

The liquid crystal display is constituted of a pair of transparent glasssubstrates 41 and 42 facing each other with a predetermined intervalleft therebetween and a liquid crystal layer 38 sandwiched by thetransparent glass substrates 41 and 42. The transparent glass substrates41 and 42 are combined and fixed with a sealing material that is notshown.

A plurality of pixel electrodes 3 constituted of ITOs and TFTs servingas active elements that are not shown are formed on the transparentglass substrate (TFT substrate) 41 with an insulation layer 44interposed therebetween, and a transparent vertical alignment film 46 ais formed such that it covers the pixel electrodes 3. Color filters 17(and a black matrix that is not shown), a common electrode (an oppositeelectrode) 48, and a vertical alignment film 46 b are formed on theother transparent glass substrate (opposite substrate) 42 in the ordermentioned. The vertical alignment films 46 a and 46 b are matched suchthat they sandwich the liquid crystal layer 38; the glass substrates 41and 42 are fixed with the sealing material; and polarizers 49 and 50 areprovided outside the substrates 41 and 42, respectively. The pixelelectrodes 3 are formed along with an active matrix (TFT matrix), anddrain bus lines 6 to which drain electrodes of TFTs are connected areshown in the illustrated example. Although not shown, gate bus lines towhich gate electrodes of the TFTs are connected are also formed. Theelectrodes may be provided on only one of the substrates.

The liquid crystal layer 38 is formed by injecting a liquid crystal froma liquid crystal injection hole provided on the sealing material. Amonomer that is optically or thermally polymerized is mixed in theliquid crystal. Further, the pixel electrodes 3 are formedwith fineslits 45 for forming an alignment pattern as shown in FIG. 7, forexample. As shown in FIG. 8, UV light irradiation or thermal processingis performed on the injected liquid crystal with a predetermined ACvoltage, i.e., an AC voltage in the range from 60 Hz to 1 kHz in thepresent embodiment, applied thereto. The applied AC voltage is arectangular wave, for example. As a result, the monomer is polymerized;polymer structures 13 that are regulated by the alignment pattern formedby the slits 45 are formed on surfaces of the liquid crystal layer 38(surfaces of the vertical alignment films 46 a and 46 b); and liquidcrystal molecules are aligned according to the alignment pattern underthe regulation of the polymer structures 13.

In the present embodiment, a liquid crystal display having 1024×768pixels at pixel pitches of 297 μm was actually fabricated.

TFT elements, drain bus lines, gate bus lines and pixel electrodesformed with fine slits for regulating alignment were formed on one ofsubstrates (a TFT substrate). Color filters and a common electrode wereformed on another substrate (opposite substrate). Glass substrates OA-2(manufactured by NIPPON ELECTRIC GLASS CO., LTD.) having a thickness of0.7 mm were used as the substrates. The fine slits were formed such thatthey extend in four directions from the center of a pixel (toward topright, bottom right, top left and bottom left parts of the same). Theslits had a width of 3 μm and intervals of 3 μm. Vertical alignmentfilms (made of polyimide) were formed on those substrates using aprinting process, and a thermal process was performed on the same for 60minutes at 180° C. The substrates were combined with spacers(manufactured by SEKISUI FINE CHEMICAL CO., LTD.) having a diameter of 4μm interposed therebetween to fabricate an open cell. A liquid crystalhaving negative dielectric constant anisotropy added with a very smallamount of a photo-polymeric monomer was injected in the cell thusobtained to fabricate a liquid crystal display panel. The dose of thephoto-polymeric monomer was 0.3% by weight.

Next, the panel was irradiated with UV rays while applying an AC voltage(10 V) at a frequency of 60 Hz which was twice that for normal drivingto the same, thereby setting the photo-polymeric monomer. The dose ofirradiation was about 4000 mJ/cm² (the wavelength was 365 nm). There wasno irregularity in the state of alignment in the pixels, and measurementcarried out after displaying a black-and-white checker pattern for 48hours revealed an image sticking rate α of 5%.

(COMPARATIVE EXAMPLE)

A comparative example for the above embodiment will now be described.The comparative example is the same as the above embodiment except thefollowing.

In setting a photo-polymeric monomer, it was irradiated with UV rayswhile applying an AC voltage (10 V) having an ordinary frequency of 30Hz to the same.

In this case, some irregularities occurred in the state of alignment inpixels unlike the above embodiment, and measurement carried out afterdisplaying a black-and-white checker pattern for 48 hours revealed animage sticking rate α of 10%.

As described above, the method of manufacturing a liquid crystal displayin the present mode for carrying out the invention makes it possible toimprove display characteristics easily and reliably without problemssuch as image sticking on display and to achieve display with highreliability.

[Third Mode for Carrying Out the Invention]

(Principle)

First, the principle of a third mode for carrying out the invention willbe described.

As a technique for improving MVA-LCDs, i.e., improving the apertureratio of the same to increase brightness and reducing the cost of thesame, the inventors have been developing an alignment regulatingtechnique in which a monomer that is optically or thermally polymerizedis mixed in a liquid crystal and is polymerized with a predeterminedvoltage applied between substrates to form polymer structures having apredetermined alignment pattern on surfaces of the liquid crystal layer(surfaces of alignment films) and to achieve stable alignment of liquidcrystal molecules with the polymer structures.

However, it was revealed that the alignment regulating techniqueproblematically causes a liquid crystal panel to perform poorly withrespect to image sticking when it is driven compared to a panel thatdoes not employ a setting method utilizing polymer structures.

Although no practical problem occurs when an image sticking rate α ofabout 5 to 6% is achieved in the same way as that in the first mode forcarrying out the invention, an image sticking rate α of about 10%results in image sticking that is noticeable and no longer ignorable toa user.

The inventors thought of controlling polymer structures such that theyhave small average surface roughness in order to prevent image sticking.

Results of an examination on a relationship between average surfaceroughness of polymer structures and the image sticking rate α are shownbelow.

In this case, a normally black mode configuration was provided by usingvertical alignment films and a liquid crystal having negative dielectricconstant anisotropy and applying polarizers on both sides of the liquidcrystal panel in a crossed Nicols configuration. Any of monoacrylate,diacrylate and triacrylate was used as a polymeric monomer; apolymerization initiator of 0.01% by weight was used; and the polymericmonomer and the polymerization initiator were mixed to a totalconcentration of 0.3% by weight. Referring to polymerizing conditions,UV rays were used in a dose in the range from 4 to 10 J/cm².

Different combinations of the polymeric monomer and the polymerizationinitiator were mixed with a liquid crystal and were injected in a liquidcrystal display. Thereafter, polymerization was performed while applyinga voltage to the liquid crystal to adjust alignment of the same, andimage sticking was evaluated. Then, the liquid crystal display wasdecomposed to observe surfaces of polymer structures formed therein withan atomic force microscope (AFM) and to study the relationship betweenaverage roughness of the same and the image sticking rate α.

The average roughness (Ra) is a value obtained from a roughness curverepresented by y=f(x) according to the following equation and FIG. 9 inwhich the roughness curve is partially. extracted in the direction of anaverage line of the same in a reference length and in which an X-axisrepresents the direction of the extracted average line and a Y-axisrepresents the direction of depth magnification (the definition is basedon JIS 80601-1994 “Definition and Indication of Average SurfaceRoughness”).Ra=1/L∫ ₀ ^(L) |f(x)|dx L: reference length

FIG. 10 shows an AFM image of a polymer structure on pixel electrodeshaving slits on a TFT substrate (the irregularities on the surface arethe polymer structure), and FIG. 11 shows a relationship between averageroughness of the surface of the polymer structure and the image stickingrate α based on the AFM image.

As shown in FIG. 11, it was revealed that the image sticking rate αdecreases with the average surface roughness and that an average surfaceroughness of 10 nm or less satisfactorily keeps the image sticking rateα in an allowable range to suppress image sticking characteristics belowa practically acceptable level. Therefore, a liquid crystal displayhaving good display characteristics can be provided by keeping theaverage surface roughness of a polymer films at 10 nm or less.

Further, results on an examination on combinations of concentrations ofthe polymeric monomer, concentrations of the polymerization initiator,and amount of irradiation of UV rays have indicated that the imagesticking rate α can be suppressed to 6% or less.

(Embodiment)

A specific embodiment will now be described based on the above-describedprinciple of the present mode for carrying out the invention withreference to FIGS. 6 to 8. The description will be made on a liquidcrystal display having major features as shown in FIG. 6. Configurationsof a TFT substrate and an opposite substrate will not be describedbecause they are similar to those in the above-described specificembodiment in the second mode for carrying out the invention.

A liquid crystal layer 38 is formed by injecting a liquid crystal from aliquid crystal injection hole provided on a sealing material. A monomerthat is optically or thermally polymerized is mixed in the liquidcrystal. Further, for example, as shown in FIG. 7, pixel electrode 3 isformed with fine slits 45 forming an alignment pattern. As shown in FIG.8, UV light irradiation or thermal processing is performed on theinjected liquid crystal with a predetermined AC voltage applied thereto.As a result, the monomer is polymerized; polymer structures 13 that areregulated by an alignment pattern formed by slits 45 are formed onsurfaces of the liquid crystal layer 38 (surfaces of vertical alignmentfilms 46 a and 46 b); and liquid crystal molecules are aligned accordingto the alignment pattern under the regulation of the polymer structures13. In the present embodiment, the polymer structures 13 are controlledsuch that they have a surface roughness of 10 nm or less.

In the present embodiment, a liquid crystal display having 1024×768pixels at pixel pitches of 297 μm was actually fabricated.

TFT elements, drain bus lines, gate bus lines and pixel electrodesformed with fine slits for regulating alignment were formed on one ofsubstrates (a TFT substrate). Color filters and a common electrode wereformed on another substrate (opposite substrate). Glass substrates OA-2having a thickness of 0.7 mm were used as the substrates. Verticalalignment films (made of polyimide) were formed on those substratesusing a printing process, and a thermal process was performed on thesame for 60 minutes at 180° C. The substrates were combined with spacers(manufactured by SEKISUI FINE CHEMICAL CO., LTD.) having a diameter of 4μm interposed therebetween to fabricate an open cell. A liquid crystalwas mixed with 0.3% by weight of photo-polymeric diacrylate monomerhaving an average molecular weight of 350 and 0.01% by weight of DAROCUR1173 (manufactured by CHIBA SPECIALTY CHEMICALS CO., LTD.) that is apolymerization initiator and injected into the open cell. Thereafter,the liquid crystal layer was irradiated with UV rays in an irradiationenergy of 4 J/cm² with a voltage of 5V DC applied thereto to formpolymer structures for controlling the alignment of the liquid crystal.At this time, the polymer structures had an average surface roughness of6 nm.

As described above, the method of manufacturing a liquid crystal displayin the present mode for carrying out the invention makes it possible toimprove display characteristics easily and reliably without problemssuch as image sticking on display and to achieve display with highreliability.

The invention is not limited to the above-described modes for carryingout the same and may be modified in various ways.

For example, although diacrylate is used as a monomer in theabove-described modes for carrying out the invention, this is notlimiting the invention, and triacrylate may obviously be used as apolymeric component to serve as a polyfunctional polymer.

Although a monomer was described as an example of a polymeric componentfor stabilization of the alignment a liquid crystal utilizing a polymerin the above-described modes for carrying out the invention, this is notlimiting the invention, and an oligomer or a mixture of an oligomer anda monomer may obviously be used as a polymeric component.

As described above, the invention makes it possible to improve displaycharacteristics easily and reliably to achieve display with highreliability by mitigating image sticking originated in the method ofregulating the direction of alignment of liquid crystal molecules duringdriving using a polymer.

1. A liquid crystal display comprising: a liquid crystal material sealedbetween two substrates provided opposite to each other; wherein theliquid crystal material includes a polymeric component that is opticallyor thermally polymerized, a polymerization initiator, and a liquidcrystal composition; and the polymerization initiator has aconcentration x that satisfies 0≦x ≦0.002 (% by weight).
 2. A liquidcrystal display according to claim 1, wherein the polymeric component ispolymerized by irradiating ultraviolet rays.
 3. A liquid crystal displayaccording to claim 1, wherein the polymeric component in the liquidcrystal material has a concentration y that satisfies 0.1≦y≦10 (% byweight).
 4. A liquid crystal display according to claim 1, wherein thepolymeric component is diacrylate.
 5. A liquid crystal display accordingto claim 1, wherein liquid crystal molecules in the liquid crystalcomposition are aligned perpendicular to surfaces of the substratesbefore the polymeric component is polymerized.
 6. A method ofmanufacturing a liquid crystal display, comprising the steps of: sealinga liquid crystal material including a polymeric component that isoptically or thermally polymerized between two substrates providedopposite to each other; polymerizing the polymeric component with avoltage applied to the liquid crystal material; and regulating thedirection of alignment of liquid crystal molecules during driving;wherein a polymerization initiator in the liquid crystal material has aconcentration x that satisfies 0≦x≦0.002 (% by weight).
 7. A method ofmanufacturing a liquid crystal display according to claim 6, wherein thepolymeric component is polymerized by irradiating ultraviolet rays.
 8. Amethod of manufacturing a liquid crystal display according to claim 6,wherein the polymeric component in the liquid crystal material has aconcentration y that satisfies 0.1≦y≦10 (% by weight).
 9. A method ofmanufacturing a liquid crystal display according to claim 6, wherein thepolymeric component is diacrylate.
 10. A method of manufacturing aliquid crystal display in which a first substrate having a firstelectrode and a second substrate having a second electrode are providedopposite to each other with an alignment film and a liquid crystal layerinterposed therebetween, the method comprising the steps of: sandwichingthe liquid crystal layer that includes a liquid crystal mixed with amonomer for aligning liquid crystal molecules in a predetermineddirection between the first substrate and the second substrate;polymerizing the monomer while applying an AC voltage between thesubstrates to form a polymer structure having a predetermined alignmentpattern; and controlling the value of the frequency of the AC voltagesuch that the speed of switching of the AC voltage is higher than thespeed of response of the liquid crystal molecules in regulating thealignment of the liquid crystal molecules with the polymer structure.11. A method of manufacturing a liquid crystal display according toclaim 10, wherein the AC voltage is a rectangular wave.
 12. A method ofmanufacturing a liquid crystal display according to claim 10, whereinthe frequency of the AC voltage is 60 Hz or more.
 13. A method ofmanufacturing a liquid crystal display according to claim 12, whereinthe frequency of the AC voltage is 1 kHz or less.
 14. A method ofmanufacturing a liquid crystal display according to claim 10, whereinthe first electrode is formed with a slit for regulating the alignmentpattern.
 15. A method of manufacturing a liquid crystal displayaccording to claim 10, wherein the monomer is polymerized by irradiatinga light or performing a thermal process on the same to form the polymerstructure.
 16. A liquid crystal display comprising: a first substratehaving a first electrode; a second substrate having a second electrodeprovided opposite to the first electrode; and a liquid crystal layerinterposed between the first and second substrates; wherein a polymerstructure is formed in the liquid crystal layer to align liquid crystalmolecules in a predetermined direction in the liquid crystal; andaverage surface roughness of the polymer structure is 10 nm or less. 17.A liquid crystal display according to claim 16, wherein the firstelectrode is formed with a slit for regulating the alignment pattern.18. A liquid crystal display according to claim 16, wherein the polymerstructure is formed by polymerizing a monomer mixed in the liquidcrystal by irradiating a light or performing a thermal process on thesame.
 19. A method of manufacturing a liquid crystal display in which afirst substrate having a first electrode and a second substrate having asecond electrode are provided opposite to each other with an alignmentfilm and a liquid crystal layer interposed therebetween, the methodcomprising the steps of: sandwiching the liquid crystal layer thatincludes a liquid crystal mixed with a monomer for aligning liquidcrystal molecules in a predetermined direction between the firstsubstrate and the second substrate; polymerizing the monomer whileapplying an AC voltage between the substrates to form a polymerstructure having a predetermined alignment pattern; and controllingaverage surface roughness of the polymer structure such that it is 10 nmor less in regulating the alignment of the liquid crystal molecules withthe polymer structure.
 20. A method of manufacturing a liquid crystaldisplay according to claim 19, wherein the first electrode is formedwith a slit for regulating the alignment pattern.
 21. A method ofmanufacturing a liquid crystal display according to claim 19, whereinthe monomer is polymerized by irradiating a light or performing athermal process on the same to form the polymer structure.